Category Archives: Tools

I wish I would have held off…

Veritas Variable Gang SawIt was just last week that I took delivery of my brand new Veritas Dovetail Saw.  I have used it several times and have gotten a lot of practice with it cutting straight lines to a marked strike line.

However, I am kicking myself today for making the move just a bit too early.

If only the folks at Veritas had let me know about their newest and most innovative saw they have ever released.  Today, the wraps were taken off of the Veritas Variable Gang Saw.

Not only is this saw made to the same high-quality specifications as the Veritas Dovetail Saw, but it goes one (actually two) better.  This triple-saw uses a dual-rod rotating axis assembly, which guarantees that by canting one blade, you can get the other to line up perfectly.

Say you want to cut a set of dovetails across the edge of a board… Simply by rotating some heavy duty brass handles, you can align a perfect 6:1, 8:1 or 14 degree dovetail pitch on each saw blade.  One full turn, and you can cut the opposite slope of the tails in one pass.

The same ease of use can be found in the adjustments to cut the pins.

This saw really takes all of the guesswork out of cutting dovetails, ensuring an airtight fit with minimal effort.

Maybe they’ll take my dovetail saw back in return?

Tools I use – my Veritas Dovetail Saw


The Veritas Dovetail Saw
This is the newest tool in my arsenal – a fresh-out-of-the-package Veritas Dovetail Saw.  It may have arrived at my home just yesterday, but the journey to this tool has taken nearly a decade.

When I first started woodworking, my first saw was a Craftsman fine toothed panel saw.  It was a great saw for what I was doing, but it was huge and – yes – I was also lured away by the siren’s song of power tools.  Through  the following years, I have gotten my hands on some large  big-box Japanese style saws, a reversible ‘dovetail’ saw that flipped on its offset handle and some entry-level Japanese style saws from some of the larger online woodworking retailers.  They all did so-so work, and I always found myself making excuses for my poor saw work.

I thought I was in the clear about a year ago when I bought a new dozuki from Lee Valley.  It did cut beautifully, but the problem I had was that getting a grip on the traditional handle was kind of tricky.  I found myself gripping the saw slightly differently every time I picked it up, and my cuts would suffer.

While at the recent Woodworking Show in Tampa, I made a beeline to the Lee Valley booth.  There they were, all of the tools in the catalogs that I had drooled over for years.  Planes, chisels and measuring devices as far as the booth stretched.  While looking at all of the goodies, I saw the new Veritas Dovetail Saw sitting on a shelf.  I had read so many reviews of it, and I had been told by several woodworkers that I might be more successful with a western-style saw, I just had to pick it up and give it a try.  I was hooked and ordered one on the spot.

The Saw in action The saw is exceptionally well made, which has been my experience with all of the hand tools I have used from the Veritas line.  It’s a substantially built saw with absolutely no wiggle or slop in the handle (which is held to the saw with post and nut similar to a plane handle).  The grip, which has been modeled after an antique saw’s, seems to fit my hand perfectly.  The grip seems small at first, but you have to realize it’s not designed for you to clench your fist over.  Simply wrap your thumb and three fingers around the handle, and point your index finger down the saw’s spine.  This way, you will be ‘pointing’ to where your saw should go.  This is a very comfortable grip, and no matter how many times I picked up the saw, my hand rested in exactly the same spot.

The saw’s teeth are angled back to 60 degrees, which is drastically different than my dozuki’s teeth, which are 90 degrees to the blade.  The product literature says it’s filed that way because it makes the saw easier to start… something I have struggled with on cheaper saws.

The Saw Kerf showdownAfter handling the saw for a while, I just had to put it to use.  I clamped a piece of red oak in my vise and started cutting.  The saw starts easily by slightly tipping the nose down and pushing gently.  Not having to worry about my grip, I was able to focus on my body positioning and arm mechanics.  The saw cuts exceptionally well, taking about a dozen strokes with very minimal downward pressure to cut a one inch deep kerf.  The stiff blade and minimal tooth set helped keep the saw on track as I worked it through the cut.

The results were impressive.  Here is the board I used with the Veritas saw cuts in the group to the left and cuts made by my dozuki on the right.  While the Japanese saw’s kerf was slightly narrower, the Veritas blade cut a very fine kerf as well.

After playing with the saw for a while, I finally buffed the blade with a little furniture paste wax, set the blade guard over the teeth and put it in the saw drawer of my tool chest.

A tool like this will be getting lots of use in my shop!

Tools I use: my band saw

This was one of those purchases I made because I ‘thought’ I should have one.  It turns out that while I don’t use it for every project, it has become an essential tool for several of them.

My Delta Band SawThis is a Delta model 28-276 14″ band saw I bought at Lowe’s about four years ago.  Oh, sure, I looked at some of those fancy smaller models (the guys at Home Depot really wanted to sell me the 12″ Ryobi band saw), but I decided on this model because 14″ is a common size for most home machines. That way, it  would accept the most common upgrades.  Boy, am I happy I considered that.

I set it up in my shop exactly as described in the manual, turned it on and – boy – was I disappointed by the performance.  Unlike my Ridgid table saw I had set up a few years earlier, I discovered that band saws take some fiddling to get them to work properly.

Yes, this is a warning to all of you prospective band saw owners – don’t be disappointed if you don’t get perfect cuts right off the bat. It take some time.

Some things I like about the saw include the blade tension release control, which means I don’t have to change the tension setting after a day at the saw.  I can just flip the tension off and take the pressure off the blade.  I also added a rolling tool stand to the purchase, so I can move the saw around the shop as necessary.

Once I got the saw tuned up – it took a day or so – things started to improve dramatically.  The saw began to track more easily.  The cuts were a little smoother.  Things were definitely looking up.

I would strongly recommend that when you buy a band saw, you get a good band saw book to go along with it.  My choice was Cutting Edge Band Saw Tips and Tricks.  A book like this will give you far more information than the manual ever could.

The monumental step in my bandsaw experiece was when I started to upgrade some items on the saw.  First up, I ditched the original blade that came with the saw and bought some replacement Viking/Timberwolf blades.  These are made of a Swedish silicon steel and cut very true.  The product manual says you can run these blades at a lower tension, but I have noticed some tracking issues if I lower the tension to the recommended levels.

I also recently added the Kreg bandsaw fence.  As with the saw, I am still in the stages of fiddling with the fence to get the best fence performance.  It is a solid and easy to use fence, so I’m sure once I get it tuned up, I’ll be in the butter zone.

I have used the saw to cut curves and resaw, and the 3/4 hp motor will sometimes struggle with harder woods.  If I slow my feed rate, I can get good performance.

Some upgrades I would like to make to the saw include adding a task light to the bottom of the top case.  Where I have the saw right now, it’s not in the best lighting situation, so that will have to be addressed.  Also, one day, I would like to add the riser block.  Sure, I’ll gain an additional 6″ of cutting capacity, but I’ll have to buy new blades.  Also, I’d like to upgrade the original steel guide block with some type of bearing system to control the blade,  but that’s something to consider in the future.

All in all, the saw has been a decent performer and has served me well.  However, if I had to do it again, I would spend the extra cash to get a more capable model which would include a more powerful motor, a larger resaw capacity, a better guide roller system, a quality stock fence and a mobile base as part of the standard package.  Probably would have cost less than the saw’s original price and the upgrade money I have spent so far.

Live and learn!

We’ve come to an understanding

The dreaded belt sanderI’d like to take a moment to introduce you to the tool I love to love – and hate.  This is my belt sander.  A Black and Decker homeowner’s model I picked up at a local Wal Mart about six years ago.

Before I go any further, yes, I am quite aware that I advertise myself as a hand tool enthusiast.  It also obviously has a tail that plugs into an outlet.  Many of you are also thinking that there is no place in the fine woodworker’s shop for one of these crude instruments of sound and dust.  Besides, it’s not even made by a ‘serious’ woodworking tool manufacturer.

It’s all true.  This bright orange baby (by the way, I believe it might be bright orange so motorists can avoid it when it’s pitched into a road) uses some of the most diminutive belts out there – 3″ x 18″.  Even it’s lousy dust bag doesn’t work any more.  I used to take the time to put it on the sander, but it developed a hole near the top zipper that just blows dust straight up into the air.  And, it’s a very hungry machine.  I affectionately call it the belt saw, because if you leave it on the work for too long, it digs out one heck of a divot in the wood.

So, why keep it?

Even in its total nastiness, it’s another one of those shop essentials I can’t seem to do without.  Just recently, I was working on my Christmas presents, I had to reach for it several times.  First when I was making the end grain cutting boards.

In my last post, I alluded to the fact that my milling and gluing operations need to become a little more exacting.  So, when I pulled them from the clamps, they were pretty uneven. So, I had to mosey down the street to the local Home Depot, where, much to my surprise, I discovered that Norton actually makes a line of sanding belts in that tiny size.  There were three grits to choose from – 50, 80 and 120, and I bought the two packs of all three grits.

While it did take the better part of a Saturday afternoon to grind the unevenness out of the boards, I knew it was much safer than trying to run the end grain boards through the planer.  With my iPod on under my hearing, breathing and eye protection, I grooved while my errors were erased totally, leaving a perfectly smooth board.  No mean feat, given that end grain is very tough stuff – making it an excellent choice for end grain cutting boards!

I changed grits to the 80, then finally to the 120 for those last very light passes, leaving just enough for me to sand out with the random orbit sander.

Later, when I tried out the Kehoe jig for a set of the photo bookends, the belt sander came out again.  I trimmed the dovetail splines as close to the work as I dared, and then used the belt sander to take them down flush with the board.

Are there better ways to accomplish these tasks?  Sure. I could get out with a block plane and use that.  But, for some reason, I seem to get better results using the belt sander for the heavy lifting and the hand tools for the fine work.

So, I’ll keep my belt sander.  For now.  It does what it does, but it does what it does pretty well.

But, I’m definitely keeping a wary eye on that tool!

Setting a proper table

The router is one of the most versatile tools in the shop.  Dovetails, mortises, tenons, decorative profiles, rabbets… the list goes on and on.

While they are extremely useful hand held, mounting them into a table dramatically expands their usefulness. I discovered this when I first bought a little bench top Skil router table for my tiny fixed-base Craftsman router.  Suddenly, I was cutting joints and profiles I never knew were possible.

Norm and his deluxe router tableThings have really changed since those early router experiments, but I still turn to my routers to do dozens of chores in my shop.  While my skill with a router has increased, so has my experience in dealing with router tables.

I’m gonna come right out and say it.  If I had the space, I would definitely build a full-blown all-the-bells-and-whistles router tables just like the one that Norm Abram built.  It would be a dedicated router station where I could do everything I would ever possibly need to. Unfortunately, in my two-car garage shop, space is at a premium, so a dedicated router station all by its lonesome is out.
The next option I considered – and built – was a table saw wing mounted router table.  It seems as if everyone who is space challenged in their shop has built or installed one, and they all seem to swear by it.  So, I went out to the local Home Depot and dipped into their scrap offcut bin.  Much to my surprise, there were two offcuts of melamine covered particleboard in the bin for a few bucks each.  So, I took ’em home, biscuited them together and with the help of a few piece of angle aluminum and some bolts, I was able to replace the right wing of my Ridgid saw.

Router table wing in sawThere.  All of my router problems were solved.  Weren’t they?  Oh, sure, the router table takes up absolutely no new space in the shop – just the footprint already reserved for the table saw.  And, I can use the table saw fence to guide my work past the bit.  I even built a pair of router fences that secure to the slots in the rip fence in case I had to bury the bit behind the fence.  All seemed ideal…

But, then it happened.  I was routing a profile on the edge of a piece of oak to make molding for a project.  Basically, I would route this profile on each of the long edges of the board and then rip them free.  That’s when it hit me – how could I use the same rip fence for both operations?  I tried setting then resetting the fence for each operation, but the pieces never seemed to come out right.

Auxiliary Router TableThat’s when I built my auxiliary router table.  Made from a sink cutout of Corian, this router table is designed to sit on a pair of sawhorses or to be clamped in the jaws of a Workmate.  Since this photo was taken, I built a fence based on a design in found in Danny Proulx’s book 50 Shop Made Jigs and Fixtures.  I even routed slots into the Corian for t-track so I could run the fence on the table.  And, in the event I ever need to bring my router table on the road, it’s ready to travel.

This setup works very well as a router table.  And maybe one day, I might consider removing the router table from my table saw’s wing.  But, since I went through all that work to begin with, I’ll just leave it there in case I ever need to use it again.

In the photos, you may have noticed that I have attached my Freud FT2000 router to a Rousseau router plate.  Permanently mounting a router base or a dedicated router to a router plate is one of the smartest ways to use a router table. This way, rather than trying to unscrew a router base from your hand held model and screwing it to a table, you can just pop the router out and mount it into another router table in mere seconds.  Sure, router plates tend to run about $40, but that cost is easily recouped after you realize just how much time it saves you.

Another important thing is that I never use a miter slot when working with a table mounted router.  Sure, they seem convenient.  However, unless you are using a self-squaring table saw style fence for your router setup, there’s a very good chance that it won’t be parallel to the fence.  What I do us use a backer push block to guide the workpiece along the fence. Not only do I get incredible control, the push block also prevents any blow-out on the back side of the work.

Hey, every shop really does need a router table.  Just take your time and carefully consider what you want to build or to buy before commiting to one.  And, if you move into a large enough shop, you’ll be certain to find plenty of space to build a proper router table to satisfy all your wishes.

Tools I Use – My measuring and marking tools

You can’t expect to do good work at woodworking if you can’t measure accurately.  Whether it’s getting an exact 45 degrees on a miter, cutting a mortise to an exact dimension or marking an 8:1 dovetail.

To help me achieve accuracy in my shop, I turn to a pretty decent selection of tools I have amassed over the past few years.

Measuring Tools

Let’s go from the back row, left to right –

A Veritas saddle square and saddle miter square.  These were some awesome scores from the folks at Lee Valley (Remember, the holidays are coming up…).  They make it easy to transfer measurements from one face of a board to another.  I find myself using these babies on almost every project.

My combination square.  Not the top of the line model – I picked this up at Woodcraft for about $35 on sale.  I’ve tested it several times and found it to be accurate.  A great tool to set blade and bit heights, mark out sections to be cut…  It’s a multi-use tool.

An electronic t-bevel gauge.  I have a regular t-bevel, but it can’t actually tell me what the angle is.  This one comes with a digital readout and makes transferring and bisecting angles a breeze.

Down a row, you see my Veritas setup blocks. I use these to set up most of my machines.  There’s nothing more sensitive than touch, and I can tell when I lay a 1/4″ bar next to a router bit, I can get it exactly to 1/4″.  I love these things!

My decimal fraction calipers.  Sure, I could get an electronic setup that goes from fractions to metric to decimal inches, but this one – so far – has answered the call.  Your work becomes a whole lot easier when you can get this kind of precision.  For instance, you can use the ‘inside’ measurement prongs to measure a mortise, then the ‘oustide’ jaws to measure the tenon… slick!

A new set of Groz dividers.  Just got this after trying to use some plastic dividers I culled from my kids’ school supply kits.  WOW, what a difference.  Great for scribing things to walls and measuring circles.

A Veritas wheel marking gauge.  I have used a wooden gauge with a pin, but this one is killer!  The wheel is easy to sharpen and gives very clean marks on the wood both with and across the grain. I have the model with the marked post, so don’t have to measure to know I’m at a particular measurement.

A good old tape measure.  Great for marking out long measurements, checking assemblies for square… I’m sure everyone has at least one.  I use a 16′ model and limit myself to just using that one for projects.  This way, I don’t run into problems if two tapes don’t quite measure up…

A tiny Groz engineer’s square. The small size makes it easy to sneak up to a table saw or band saw blade to ensure things are square.  Very handy..

Finally, a Veritas marking knife. This one is awesome, because you can use it either left or right handed.  The back side of the knife is dead flat, so you can run it along a straight edge to get a crisp mark.  And, nothing beats the accuracy of a clean slice when you absolutely, positively have to make the cut the right size.

Some things that didn’t make the photo include a carpenter’s square, some speed squares, and two steel rules… one a center finding model.

By using these tools and taking my time, I can get pretty decent results in my woodworking.